Engine efficiency

Mathematical definition

The efficiency of engine is defined as ratio of the useful work done to the heat provided.

where, Q 1 is the heat absorbed and Q 1 − Q 2 is the work done.

Please note that the term work done relates to the power delivered at the clutch or at the driveshaft.

This means the friction and other losses are subtracted from the work done by thermodynamic expansion. Thus an engine not delivering any work to the outside environment has zero efficiency.

Compression ratio

The efficiency of internal combustion engines depends on several factors, the most important of which is the expansion ratio. For any heat engine the work which can be extracted from it is proportional to the difference between the starting pressure and the ending pressure during the expansion phase. Hence, increasing the starting pressure is an effective way to increase the work extracted (decreasing the ending pressure, as is done with steam turbines by exhausting into a vacuum, is likewise effective).

Most gasoline (petrol) and Diesel engines have an expansion ratio equal to the compression ratio (the compression ratio calculated purely from the geometry of the mechanical parts) of 10:1 (premium fuel) or 9:1 (regular fuel), with some engines reaching a ratio of 12:1 or more. The greater the expansion ratio the more efficient is the engine, in principle, and higher compression / expansion -ratio conventional engines in principle need gasoline with higher octane value, though this simplistic analysis is complicated by the difference between actual and geometric compression ratios. High octane value inhibits the fuel's tendency to burn nearly instantaneously (known as detonation or knock) at high compression/high heat conditions. However, in engines that utilize compression rather than spark ignition, by means of very high compression ratios (14-25:1), such as the diesel engine or Bourke engine, high octane fuel is not necessary. In fact, lower-octane fuels, typically rated by cetane number, are preferable in these applications because they are more easily ignited under compression.

Under part throttle conditions (i.e. when the throttle is less than fully open), the effective compression ratio is less than when the engine is operating at full throttle, due to the simple fact that the incoming fuel-air mixture is being restricted and cannot fill the chamber to full atmospheric pressure. The engine efficiency is less than when the engine is operating at full throttle. One solution to this fact is to shift the load in a multi-cylinder engine from some of the cylinders (by deactivating them) to the remaining cylinders so that they may operate under higher individual loads and with correspondingly higher effective compression ratios. This technique is known as variable displacement.

Some engines such as the Atkinson or Miller /Atkinson cycle achieve increased efficiency by having an expansion ratio larger than the compression ratio.

Diesel engines have a compression / expansion ratio between 14:1 to 25:1. In this case the general rule does not apply because Diesels with compression ratios over 20:1 are indirect injection diesels. These use a prechamber to make possible high RPM operation as is required in automobiles and light trucks. The thermal and gas dynamic losses from the prechamber result in direct injection Diesels (despite their lower compression / expansion ratio) being more efficient.

Friction

An engine has many moving parts that produce friction. Some of these friction forces remain constant (as long as applied load is constant); some of these friction losses increase as engine speed increases, such as piston side forces and connecting bearing forces (due to increased inertia forces from the oscillating piston). A few friction forces decrease at higher speed, such as the friction force on the cam's lobes used to operate the inlet and outlet valves (the valves' inertia at high speed tends to pull the cam follower away from the cam lobe). Along with friction forces, an operating engine has pumping losses, which is the work required to move air into and out of the cylinders. This pumping loss is minimal at low speed, but increases approximately as the square of the speed, until at rated power an engine is using about 20% of total power production to overcome friction and pumping losses.

Oxygen

Air is approximately 21% oxygen. If there is not enough oxygen for proper combustion, the fuel will not burn completely and will produce less energy. An excessively rich fuel to air ratio will increase unburnt hydrocarbon pollutants from the engine. If all of the oxygen is consumed because there is too much fuel, engine's power is reduced.

As combustion temperature tends to increase with leaner fuel air mixtures, unburnt hydrocarbon pollutants must be balanced against higher levels of pollutants such as nitrogen oxides (NOx), which are created at higher combustion temperatures. This is sometimes mitigated by introducing fuel upstream of the combustion chamber to cool down the incoming air through evaporative cooling. This can increase the total charge entering the cylinder (as cooler air will be more dense), resulting in more power but also higher levels of hydrocarbon pollutants and lower levels of nitrogen oxide pollutants. With direct injection this effect is not as dramatic but it can cool down the combustion chamber enough to reduce certain pollutants such as nitrogen oxides (NOx), while raising others such as partially decomposed hydrocarbons.

The air-fuel mix is drawn into an engine because downward motion of the pistons induces a partial vacuum. A compressor can additionally be used to force a larger charge (forced induction) into the cylinder to produce more power. The compressor is either mechanically driven supercharging or exhaust driven turbocharging. Either way, forced induction increases the air pressure exterior to the cylinder inlet port.

There are other methods to increase the amount of oxygen available inside the engine; one of them, is to inject nitrous oxide, (N2O) to the mixture, and some engines use nitromethane, a fuel that provides the oxygen itself it needs to burn. Because of that, the mixture could be 1 part of fuel and 3 parts of air; thus, it is possible to burn more fuel inside the engine, and get higher power outputs.

Gasoline (petrol) engines

Modern gasoline engines have a maximum thermal efficiency of about 25% to 30% when used to power a car. In other words, even when the engine is operating at its point of maximum thermal efficiency, of the total heat energy released by the gasoline consumed, about 70-75% is rejected as heat without being turned into useful work, i.e. turning the crankshaft. Approximately half of this rejected heat is carried away by the exhaust gases, and half passes through the cylinder walls or cylinder head into the engine cooling system, and is passed to the atmosphere via the cooling system radiator. Some of the work generated is also lost as friction, noise, air turbulence, and work used to turn engine equipment and appliances such as water and oil pumps and the electrical generator, leaving only about 25-30% of the energy released by the fuel consumed available to move the vehicle.

At idle, the thermal efficiency is zero, since no usable work is being drawn from the engine. At low speeds, gasoline engines suffer efficiency losses at small throttle openings from the high turbulence and frictional (head) loss when the incoming air must fight its way around the nearly closed throttle; diesel engines do not suffer this loss because the incoming air is not throttled. At high speeds, efficiency in both types of engine is reduced by pumping and mechanical frictional losses, and the shorter period within which combustion has to take place. Engine efficiency peaks in most applications at around 75% of rated engine power, which is also the range of greatest engine torque (e.g. in most modern passenger automobile engines with a redline of about 6,000 RPM, maximum torque is obtained at about 4,500 RPM, and maximum engine power is obtained at about 6,000 RPM). At all other combinations of engine speed and torque, the thermal efficiency is less than this maximum.

A gasoline engine burns a mix of gasoline and air, consisting of a range of about twelve to eighteen parts (by weight) of air to one part of fuel (by weight). A mixture with a 14.7:1 air/fuel ratio is said to be stoichiometric, that is when burned, 100% of the fuel and the oxygen are consumed. Mixtures with slightly less fuel, called lean burn are more efficient. The combustion is a reaction which uses the air's oxygen content to combine with the fuel, which is a mixture of several hydrocarbons, resulting in water vapor, carbon dioxide, and sometimes carbon monoxide and partially burned hydrocarbons. In addition, at high temperatures the oxygen tends to combine with nitrogen, forming oxides of nitrogen (usually referred to as NOx, since the number of oxygen atoms in the compound can vary, thus the "X" subscript). This mixture, along with the unused nitrogen and other trace atmospheric elements, is what we see in the exhaust.

In the past 3–4 years, GDI (Gasoline Direct Injection) increased the efficiency of the engines equipped with this fueling system up to 35%. Currently, the technology is available in a wide variety of vehicles ranging from less expensive cars produced by Mazda, Ford and Chevrolet to more expensive cars produced by BMW, Mercedes-Benz, and Volkswagen Auto Group.

Diesel engines

Engines using the Diesel cycle are usually more efficient, although the Diesel cycle itself is less efficient at equal compression ratios. Since diesel engines use much higher compression ratios (the heat of compression is used to ignite the slow-burning diesel fuel), that higher ratio more to air pumping losses within the engine.

Modern turbo-diesel engines use electronically controlled common-rail fuel injection to increase efficiency. With the help of geometrically variable turbo-charging system this also increases the engines' torque at low engine speeds (1200-1800RPM).

Gas turbine

The gas turbine is most efficient at maximum power output in the same way reciprocating engines are most efficient at maximum load. The difference is that at lower rotational speed the pressure of the compressed air drops and thus thermal and fuel efficiency drop dramatically. Efficiency declines steadily with reduced power output and is very poor in the low power range - the same is true in reciprocating engines, the friction losses at 3000 RPM are almost the same whether the engine is under 10% load or not having any useful output on the driveshaft. The inertia of high speed gas turbine together with the low air pressure under low speed cause it to have a significant lag which many drivers are unwilling to cope with. Today the gas turbine is not used for automobiles and trucks because the usage patterns dictate varying loads, including idling speeds. General Motors at one time manufactured a bus powered by a gas turbine, but due to the economy where crude oil prices rose exponentially (1970's) this concept was abandoned. Rover, Chrysler, and Toyota also built prototypes of turbine powered cars, Chrysler building a short prototype series of them for real-world evaluation. Driving comfort was good, but overall economy lacked due to reasons mentioned above. This is also why gas turbines can be used for permanent and peak power electric plants. In this application they are only run at or close to full power where they are efficient or shut down when not needed.

Gas turbines do have advantage in power density - gas turbines are used as the engines in heavy armored vehicles and armored tanks and in power generators in jet fighters.

One other factor negatively affecting the gas turbine efficiency is the ambient air temperature. With increasing temperature, intake air becomes less dense and therefore the gas turbine experiences power loss proportional to the increase in ambient air temperature.